Systems and methods for forming shaped ice

ABSTRACT

An automatic shaped ice system for forming and dispensing three-dimensional shaped ice pieces. The system includes a control module, a user interface, an ice maker module, and a storage and dispensing module. The ice maker module includes a plurality of shaped ice units, which include movable two-piece molds for forming the shaped ice pieces and transferring them into the storage and dispensing module for dispensing upon a user request input via the user interface. The shaped ice pieces may be of a plurality of different shapes, and organized into different categories for dispensing such that a user may select from a category and receive shaped ice pieces relating to that category.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates generally to methods and systems for making and dispensing ice, and more specifically to methods and systems for making and dispensing shaped ice.

Discussion of the Related Art

Ice machines commonly known in the art include hotel ice machines, commercial ice machines, beverage machines, and ice dispensers incorporated into refrigerators. Ice machines typically include elements for making the ice, including a water supply, an see cube mold, and a refrigeration unit. Ice machines also typically include elements for dispensing the ice, including an ejector and a holding container.

A typical operation of the ice machine includes temporarily opening an automatic water valve coupled to a potable water source. When the valve is open, water flows into the ice cube mold, which is located in a portion of the ice machine held at a freezing temperature. Some ice cube molds include a coating to allow for easier removal of the ice.

After a thermostat sense that the ice cubes are fully frozen, the machine activates a motor and heater. The heater loosens the ice cubes from the mold, and the motor operates the ejector/harvesting arm, removing the ice cubes from the ice cube mold.

Commercial and food service ice machines accomplish rapid ice formation by placing the evaporator coils of the refrigeration unit in close contact with the area to be frozen, using convection to freeze the ice rather than conduction through air.

Various shapes of ice cubes formed by ice machines are known in the art. Shapes include crescents, tubes, full cubes, half cubes, flakes, and bullet-shaped.

SUMMARY OF THE INVENTION

In one embodiment the invention can be characterized, as an automatic shaped ice system comprising: a control module coupled and configures to operatively control an ice making module, an ice dispensing module, and a user interface; the ice making module including a plurality of molds for forming a plurality of shaped see pieces, the module configured to receive water from a water source and supply the water to at least one mold, freeze the at least one mold, and remove the plurality of shaped ice pieces from the molds, wherein the plurality of molds produces a plurality of ice shapes; the ice dispensing module configured to receive the ice shapes from the ice making module and store the ice shapes in a plurality of storage bins, wherein each storage bin stores a different combination of ice shapes from the other storage bins; and the user interface configured to receive a user selection for a combination of ice shapes stored in at least one of the storage bins, whereby the selected combination of ice shapes is dispensed by the ice machine.

In another embodiment, the invention can be characterized as a process for an automatic shaped ice system comprising the steps of selecting, by a user from a user interface of the automatic shaped ice system, of at (east one category of shaped ice, whereby a control module coupled to the user interface receives the category selection; sending, by the control module, in response to receiving the category selection, of a dispensing command to a storage and dispensing module of the automatic shaped ice system; dispensing of shaped ice from at least one storage bin of the storage and dispensing module, the storage bin storing shaped ice, wherein the at least one storage bin corresponds to the at least one category; sending, by the control module, of at least one command to an ice maker module of the automatic shaped ice system for forming additional shaped ice pieces.

In yet another embodiment, the invention may be characterized as a shaped ice unit for an automatic shaped ice system, comprising: a frame including two vertical sidewalls located on opposite sides of the frame; a generally vertical track located in each sidewall; a top mold removably coupled to a portion of the frame near the top of the sidewalls, wherein the top mold is located between the sidewalls, and wherein the top mold is oriented in a horizontal position, and configured to receive water from a water line of the automatic shaped ice system, and wherein the top mold, includes a plurality of downward-facing cavities for forming shaped ice pieces; a bottom mold located between the sidewalls and movably coupled to each sidewall track, whereby at a top position the bottom mold is coupled to the top mold, the bottom mold including a plurality of cavities configured to form three-dimensional shapes when matched with the cavities of the top mold; two flanges coupled to the bottom mold, wherein each and is coupled proximate to a sidewall, each flange generally perpendicular to a horizontal plane of the bottom mold and extending generally downward when the bottom mold is in a horizontal position, each flange including two generally parallel arm and a channel formed between the arms; two track plates oriented parallel, to the sidewalls, each track plate pivotally coupled at one end to an inside face of the proximate sidewall by an upper holt located proximate to the top mold, each track plate including a curved rod track; a cylindrical rod coupled to the bottom mold and oriented horizontally, the rod passing through each rod track and each vertical track and spanning between the sidewalls, whereby movement of the rod is constrained by the rod tracks and the vertical tracks, and wherein when the bottom mold is in the top position the rod is in a top position; and a pivot bolt projecting inward from each sidewall and extending through each flange channel, whereby when the rod is moved downward from the top position, the bottom mold moves downward to a bottom position, and rotates approximately 180 degrees, whereby ice pieces formed when the top mold is coupled to the bottom mold are inverted, whereby gravity causes the ice pieces to fail from the bottom mold.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features and advantages of several embodiments of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings.

FIG. 1 is a schematic diagram of a shaped ice system in accordance with one embodiment of the present invention.

FIG. 2 is a schematic diagram of a portion of an ice maker module and a storage and dispensing module of the shaped ice system.

FIG. 3 is a perspective view of a shaped ice unit of the ice maker module.

FIG. 4 is an exploded view of the shaped ice unit.

FIG. 5 is a perspective view of the shaped ice unit in a molding position

FIG. 6 is a perspective view of the shaped ice unit in an intermediate position.

FIG. 7 is a perspective view of the shaped ice unit in an unmolding position.

FIG. 8 is a front elevational view of two shaped ice units in accordance with one embodiment of the present invention.

FIG. 9 is a perspective view of a portion of the shaped ice units shown in FIG. 8.

FIG. 10 is a perspective view of a top mold of the shaped ice unit.

FIG. 11 is an underside perspective view of the top mold.

FIG. 12 is a flowchart diagram of a process for dispensing ice using the shaped ice system.

FIG. 13 is a user interface for the shaped ice system m accordance with one embodiment of the present invention.

Corresponding reference characters indicate corresponding components throughout the several views of the drawings. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention.

DETAILED INSCRIPTION

The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of exemplary embodiments. The scope of the invention should be determined with reference to the claims.

Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, such as examples of programming, software modules, user selections, network transactions, database queries, database structures, hardware modules, hardware circuits, hardware chips, etc., to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without, one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

Referring first to FIG. 1, a schematic diagram of a shaped ice system 100 is shown in one embodiment of the present invention. Shown are a potable water source 102, an ice maker module 104, a control module 106, a user interface 108, a storage and dispensing module 110 including a plurality of storage bins 112, a plurality of shaped ice pieces 114, a plurality of operative couplings 116, and a plurality of ice transfers 118.

The control module 106 comprises at least one processor, non-transitory memory coupled to the processor, and software configured to run on the processor, The control module 106 is configured to perform the functions required to monitor and control the ice-making process, receive input from the user interface 108, and send commands to the other components of the shaped ice system 100. In one embodiment the processor is an Arduino microprocessor, although other processor types, for example Raspberry Pi microprocessors, may be used. In one embodiment, a Raspberry Pi microprocessor and an Arduino microprocessor are used in conjunction, with the Arduino receiving the signals from and/or controlling at least thermocouples, infrared sensors, motor couples, stepper motors, actuators, and the temperature of the freezing stations, and the Raspberry Pi. The Raspberry Pi would control the user interface 108 and translate the touchscreen commands for the Arduino.

The control module 106 is operatively coupled to and controls the ice maker module 104. The ice maker module 104 is configured to receive potable water from the external water source 102, and produce the shaped ice pieces 114. The ice maker module 104 is described in more detail below in FIG. 2. The ice maker module 104 is configured to deposit the shaped ice pieces 114 into the storage and dispensing module 110.

The control module 106 is operatively coupled to the user interface 108. The user interface 108 may be of any type that can receive input and indicate user selections. In one embodiment, the user interface 108 is a touch screen display. In another embodiment, the user interface 108 is a 7″ LCD display with a resolution of 1280×800. The user interface 108 is shown in more detail below in FIG. 12.

The control module 106 is also operatively coupled to the storage and dispensing module 110, wherein, based on user input received via the user interface 108, the control module 106 operates individual dispensers of the storage and dispensing module 110, thereby dispensing the shaped ice pieces 114. In one embodiment, the storage and dispensing module 110 includes a storage area per bin 112 of approximately 120 cubic inches or 2 pounds of ice. In one embodiment a total ice storage capacity is approximately 37.5 pounds of ice.

The shaped ice system 100 in one embodiment is configured to be in compliance with applicable current codes and standards for food items, such as the NSF/ANSI December 2012 standard for automatic ice-making equipment.

In one embodiment, the overall size of a housing of the shaped ice system 100 is approximately 2 feet wide×3 feet long×3 feet wide. The housing is comprised of sheet metal casing.

In one embodiment, electrical systems of the ice system 100 are configured to connect to a standard 120V wall outlet to allow for installation in a wide variety of environments. In other embodiments, the electrical systems may be configured to connect to a standard 220V wall outlet.

Referring next to FIG. 2, a schematic diagram of the ice maker module 104 and a storage bin portion of the storage and dispensing module 110 are shown in accordance with one embodiment of the present invention. Shown are the potable water source 102, the plurality of storage bins 112, the plurality of ice transfers 118, a holding tank 200, a plurality of water lines 202, a plurality of shaped ice units 204, a water injection manifold 206, and a plurality of solenoid valves 208.

The ice maker module 104 is based on commercial ice making systems as commonly known in the art. In one embodiment, the ice maker unit includes a refrigerator condenser unit coupled to evaporator coils. The evaporator coils are placed proximate to the area to be frozen. The ice maker module 104 receives water from the external water source 102 shown in FIG. 1. In one embodiment the water is stored in the holding tank 200. The holding tank 200 may include a float valve for regulating the water level in the holding tank 200. The holding tank 200 is fluidly coupled to the water injection manifold 206. In one embodiment the manifold 206 includes a plurality of solenoid valves 208. Each solenoid valve 208 is also coupled to the control module 106, which operates the solenoid valves 208 as required to release the appropriate amount of water for that shaped ice unit 204. The coupling of the solenoid valve 208 to the shaped ice unit 204 may include dividing the water flow into a plurality of tubes, such that each tube carries water flow into one shaped ice cavity of the shaped ice unit 204, i.e., if the shaped ice unit 204 includes 8 shaped ice cavities, 8 tubes would couple the shaped ice unit 204 to the solenoid valve 208. For clarity, the exemplary water injection manifold 206 shown includes 6 solenoid valves 208. It will be understood by those of ordinary skill in the art that the number of solenoid valves 208 of the water injection manifold 206 may vary. In one example, the water injection manifold 206 may include 8 solenoid valves 208. Additionally, multiple water injection manifolds 206 may be coupled to the holding tank 200. Each solenoid valve 208 is opera lively coupled to and controlled by the control module 106.

In some embodiments the coupling of the water tube to the shaped ice unit 204 includes a tapered nozzle to accelerate the How and provide a spray to more quickly freeze the water.

Each solenoid valve 208 is fluidly coupled to one of the plurality of shaped ice units 204. The shaped ice units 204 are described in more detail in FIGS. 3-10. The shaped ice unit 204 includes a shaped ice mold for forming a plurality of shaped ice pieces 114. Each mold may comprise the same shape (e.g. stars) or a plurality of shapes (e.g. stars and spheres). When the control module 106 opens the valves fluidly coupled to the shaped ice unit 204, water flows into and fills cavities of the shaped ice unit. The control module 106 then closes the valve 208. The ice maker module 104 then freezes the water, forming the shaped ice pieces 114. After the ice is formed, the control module 106 directs the shaped ice unit 204 to dispense the shaped ice pieces 114.

As shown in the exemplary ice maker module 104 of FIG. 2, the ice maker module 104 includes 6 shaped ice units 204. Each shaped ice unit 204 is coupled to one storage bin 112 such that the storage bin 112 receives the shaped ice pieces 114 from one shaped ice unit 204. It will be appreciated by those of ordinary skill in the art that the number of shaped ice units 204 and storage bins 112 is for exemplary purposes only, and as few as one shaped ice unit/storage bin combination, or as many as the ice system 100 is configured to accommodate, may be included in the ice system 100.

In one embodiment the shaped ice pieces 114 fell from a bottom mold 304 of the shaped ice unit 204 into the storage bin 112 located beneath the shaped ice unit 204. The storage bin 112 may be of any available storage bin type configured to catch and receive all ice pieces 114 falling from the bottom mold 304. The size of each storage bin 112 may be determined by a desired, ice storage capacity and/or a desired footprint of the system 100. In the present embodiment, each storage bin 112 includes approximately 120 cubic inches of ice storage capacity. In some embodiments, the storage volumes of the storage bins 112 may vary to provide more or less storage capacity for specific ice shapes. In one embodiment the storage bins 112 are of a plastic material, although other suitable material, such as metal, may be used. The storage bins 112 are configured with an opening allowing the ice to be dispensed. In one embodiment, each storage bin 112 includes an agitator/dispenser assembly configured to agitate the ice and allow portions of the ice to pass through the opening. The agitator/dispenser assembly is operatively coupled to the control module 106, which activates the agitator/dispenser assembly in response to user input received via the user interface 108. In one embodiment, the user placing a cup against a sensor sends an input to the control module to activate the agitator/dispenser assembly as long as the cup is activating the sensor. In one embodiment, tubes or sheet metal tracks ate used to convey the ice pieces 114 to the opening.

Referring next to FIGS. 3 and 4, an exemplary shaped ice unit 204 is shown in one embodiment of the present invention. A perspective view is shown in FIG. 3, with the bottom mold in a lower position. An exploded view is shown in FIG. 4, with the bottom mold in a middle position. Included in the shaped ice unit are an evap plate 300, a top mold 302, the bottom mold 304, a plurality of bottom mold cavities 306, a first sidewall 308, four arms 310, a bottom mold frame 312, two flanges 314, two vertical tracks 316, a flip rod 318, two channels 320, two track plates 322, a second sidewall 324, a plurality of top mold cavities 326, two support bars 328, two upper bolts 330, two pivot bolts 332, two rod tracks 334, and a shaped ice unit, front side 336.

A frame of the shaped ice unit includes the vertical sidewalls 308, 324 which are in a generally rectangular plate shape. The shaped ice unit 204 is generally box-shaped, with the vertical sidewalls 308, 324 forming the sides of the box. The distance between the two sidewalls 308, 324 is approximately 8 inches. Each sidewall 308, 324 includes the generally vertical track 316.

The top mold 302 is a generally rectangular shape, with a thickness as required to accommodate the top mold cavities 326 and provide adequate stiffness and durability of the top mold 302. The top mold 302 is removably coupled between the sidewalls 308, 324 in a horizontal position, i.e. in the position of the top of the box-shape. The rectangular evap plate 300 is coupled to a top surface of the top mold 302. The evap plate 300 and the top mold 302 are configured to receive water from the water line 202 fluidly coupled to the holding tank 200, and include water access holes 338 as necessary to receive the water in the molds 302, 304. The top mold 302 includes the plurality of downward-facing cavities 326 for forming the ice pieces 114.

At a base of each sidewall 308, 324, two support bars 328 of the frame connect the first sidewall 308 to the second sidewall 324 to provide additional frame stability to the shaped ice unit 204. In the present embodiment outer dimensions of the shaped ice unit 204 are approximately 10 inches high×5 inches wide×10 inches long.

The bottom mold 304, which when coupled to the top mold 302 forms the three-dimensional mold for the shaped ice pieces 114, is located between the sidewalls 308, 324 underneath the top mold 302, and is movably coupled to the track plates 322 and the pivot bolts 332. When the top mold 302 is coupled to the bottom mold 304, a watertight seal is formed between the two molds 302, 304. In one embodiment, the seal, is provided by a rubber gasket adhered to either the top mold 302 or the bottom mold 304. The bottom mold 304 includes the plurality of cavities 306 on one side of the mold 304 such that when the bottom mold 304 is in an upper, horizontal position and coupled to the top mold 302, the top mold cavities 326 and the bottom mold cavities 306 are matched, forming a plurality of cavities forming three-dimensional shapes. The cavities 306, 326 are configured such that the ice pieces 114 are releasable from the molds when the bottom mold 304 is lowered and removed from the top mold 302. i.e., the molds 302, 304 include no reverse draft angles that would prevent the ice from being released from the molds 302, 304.

In the embodiment shown, the bottom mold 304 is coupled to the bottom mold frame 312 on a side of the bottom mold opposite to the bottom mold cavities 306. Two flanges 314 are coupled to the bottom mold frame 312, one flange 314 on each sidewall 308, 328 side. The flanges 314 are generally perpendicular to the bottom mold 304 and extend generally downward when the bottom mold 304 is in the upper, horizontal position and coupled to the top mold 302. In the lower horizontal position shown in FIG. 3, the flanges 314 extend generally upward. Each flange 314 includes two parallel arms 310 extending away from the bottom mold and the channel 320 between each pair of arms 310, such that a portion of each flange 314 distal to the bottom mold is generally U-shaped, with the base of the U proximate to the bottom mold. It will be appreciated that in some embodiments the bottom mold frame 312 may not be included and the flanges 314 may be coupled directly to the bottom mold 304.

The bottom mold frame 312 includes the flip rod 318 oriented normal to the flanges 314, i.e. spanning between the frame sidewalls 308, 324. The flip rod 318 is located between the base of the U-shaped arms 310 and the bottom mold 304. Each end of the flip rod 318 passes through the rod track 334 of the proximate track plate 322 and through the vertical track 316 of the proximate sidewall 308, 324, such that the movement of the flip rod 318 is constrained by a path of the flip rod 318 within the tracks 316 and 334. An upper end of each track plate 322 is pivotally coupled to an upper inside portion of the proximate sidewall 308, 324 by the upper bolt 330. The track plate 322 is generally parallel to the proximate sidewall 308, 324, with the rod track 334 oriented in a generally vertical direction. The rod track 334 includes a C-shaped portion curving towards the front side 328 of the shaped ice unit 204 in a middle portion of the rod track 334. At each sidewall 308, 324 location, the pivot bolt 332 located at a middle portion of the track plate 322 distal to the front side 328, pivotally couples the proximate flange 314 to the track plate 322. A pivot bolt shaft passes through the channel 320 of the flange 314, whereby the flange 314 may rotate with respect to the track plate 322, and the translational movement of the bottom mold frame 312 is constrained, by the sliding of the pivot bolt shaft in the channel 320. The shaped ice unit 204 is thus configured such that, as the flip rod 318 is moved downward in the rod track 334 from the upmost position (i.e. the position where the top mold 302 is coupled to the bottom mold 304), the bottom mold 304 moves downward with the flip rod 318. The combination of the shape of the rod track 334, the pivoting of the track plate 322 around the upper bolt 330, the pivoting of the flange 314 around the pivot bolt 332, and the sliding of pivot bolt 332 within the flange arms 310 combine to form a mechanism that, during the downward, movement of the flip rod 318, results in the bottom mold frame 312 and bottom mold 304 rotating approximately 180 degrees, such that when the flip rod 318 has moved to the bottommost position, the bottom, mold 304 has been flipped so that the bottom mold cavities 306 are facing generally downwards. The movement of the mechanism and the bottom mold 304 are described further below in FIGS. 5-7.

The shaped ice unit 204 is similar in function to a conventional self-inking stamp unit. The top mold 302 and the bottom mold 304 are supported in several positions, as required for filling fee mold, freezing the ice pieces 114, and then removing the ice pieces 114 from the mold. The structural configuration shown in FIG. 3 allows the top mold 302 and the bottom mold 304 to be coupled together for filling with water and the subsequent freezing. When the ice pieces 114 have been frozen, the flip rod 318 is moved downward, resulting in the bottom mold 304 de-coupling from the top mold 302, and rotating such that the ice pieces 114 are facing downward, where they fall into the storage bin 112 below (not shown). The flip rod 318 is then moved in reverse (i.e. upwards) back to the initial position, and a new set of shaped ice pieces 114 may be formed.

The materials of the structural portion of the shaped ice unit 204 may be any material, suitable to support the overall structure and provide for operation of the mechanism as described herein. In some embodiments, most portions of the shaped ice unit are acrylic. In other embodiments, portions of the shaped ice unit may be plastic or metal.

Referring next to FIGS. 5-7, the shaped ice unit 204 is shown in an upper (molding) position in FIG. 5, an intermediate position in FIG. 6, and a lower (unmolding) position in FIG. 7. Shown are the storage bin 112, ice pieces 114, the evap plate 300, the top mold 302, the bottom mold 304, the bottom mold cavities 306, the first sidewall 308, the arms 310, the bottom mold, frame 312, the bottom mold frame flanges 314, the vertical tracks 316, the flip rod 318, the channels 320, the track plates 322, the second sidewall 324, the top mold cavities 326, the support bars 328, the upper bolts 330, the pivot bolts 332, the rod tracks 334, and the front side 336.

In FIG. 5, the bottom mold 304 is in the uppermost, molding, position, and is coupled to the top mold 302. The freezing process may be any ice cube freezing process known in the art and suitable for the shaped ice process. In one embodiment, an evaporator is set to −15° F., with a fan on the evaporator controlling the convective heat transfer rate. The vapor compression cycle has a cooling capacity of 940 BTU/hr. Temperature sensors are used to keep the storage bins 112 at a constant temperature of 28° F. Prior to filling, the fan will turn off, and a resistance wire 902 coupled to the molds 302, 304 (as shown in more detail below in FIG. 9) will be heated. The molds 302, 304 are then filled with water using the water access holes 338 fluidly coupled to one solenoid valve 208 as previously described in FIG. 2, and the resistance wire 902 is turned off. After the molds 302, 304 are tilled with water, the control module 106 activates the freezing process.

After the shaped ice pieces 114 are frozen, the fen will turn off and the resistance wire 902 heated to loosen the shaped ice pieces 114 from the mold 302, 304.

In FIG. 6, after the ice pieces 114 have been heated, the control module 106 sends a signal to the shaped ice unit 204, activating the actuator 800 coupled to the flip rod 318. The actuator 800 pulls the flip rod 318 downward through the vertical track 316 on each sidewall 308, 324. The bottom mold frame 312, being coupled to the flip rod 318, moves downward with the flip rod 318. The flip rod 318 and the vertical tracks 316 are configured such that the flip rod 318 (and consequently the bottom mold frame 312) may rotate while moving downward. While the flip rod 318 is moving downward, the movement of the flip rod 318 is also dictated by the rod track 334 of the track plate 322. Each track plate 322 is coupled to the proximate sidewall 308, 324 by the pivoting connection of the upper bolt, allowing the track plate 322 to swing from front to back. As the flip rod 318 moves downward, the track plate 322 swings away from, the front side 336 of the shaped ice unit 204. Simultaneously, the arms 310 of the bottom mold frame flanges 314, with the pivot bolt 332 interposed between each set of arms 310, move past the pivot bolt 332 such that a distance between the pivot bolt 332 and the bottom mold frame 312 is decreased. The combination of the pivoting track plate 322, the curvature of the rod tracks 334, and the movement of the arms 310 past the pivot bolt 332 rotate the bottom mold 304 towards the front side 336 as the bottom mold 304 is lowered, as shown in FIG. 6. As the flip rod 318 continues to be lowered by the actuator 800, the bottom mold 304 continues to lower and rotate.

In FIG. 7, the rod 318 has been moved to the downward-most position. The bottom mold 304 has continued to rotate as it moves downward, resulting in an inverted position when the rod 318 is in the downward-most position. The ice pieces 114 then fall downward, from gravity, from the bottom mold 304 into the storage bin 112 located below the shaped ice unit 204. To reset the shaped ice unit 204, the control module 106 sends the actuator 800 a signal to return to the initial molding position. The flip rod 318 is then moved upward and the process is reversed.

In one embodiment, the shaped ice unit is configured to complete the entire process of forming and unmolding the shaped ice pieces 114 in approximately 5 minutes. The freezing time is approximately 2-5 minutes.

Referring next to FIG. 8, a from elevational view of two shaped ice units 802, 804 is shown in one embodiment of the present invention. Shown are evap plates 300, top molds 302, bottom molds 304, the bottom mold cavities 306, first sidewall 308, bottom mold frames 312, flanges 314, the flip rod 318, the track plates 322, the second sidewall 324, the support bars 328, the upper bolts 330, the pivot bolts 332, the actuator 800, the first ice unit 802 and the second ice unit 804.

In the embodiment shown, in FIG. 8, two shaped ice units 802, 804 comprising the first ice unit 802 and the second shaped see unit 804 are shown. The units 802, 804 are aligned such that the sidewalls 308, 324 are parallel. The actuator 800 is located between the two shaped ice units 802, 804, i.e. between the second sidewall 324 of the first unit 802 and the first sidewall 308 of the second unit 804. The proximate sidewalls 308, 324 are spaced approximately 2 inches apart. The actuator 800 is configured to actuate in a vertical direction, and is coupled to the flip rod 318, which is then coupled to both shaped, ice units 802, 804 as previously described in FIGS. 3-7. The position shown in FIG. 8 is a lower position, similar to that shown in FIG. 7.

The actuator 800 is coupled to a power source, in one embodiment a 12V power supply, and is operatively controlled by the control module 106. In the configuration shown, the actuator 800 moves the flip rod 318 for both units 802, 804, enabling the two shaped ice units 802, 804 to be controlled simultaneously by only one actuator 800. While two shaped ice units 802, 804 are shown in FIG. 8, it will be understood that a single actuator/rod assembly may operate more than two shaped Ice units 204, for example, 4 or 6 shaped ice units 204. In other embodiments, each shaped ice unit 204 would have a dedicated actuator 800. In yet another embodiment multiple actuators 800 are used for a single shaped ice unit 204.

The actuator 800 is configured to move the flip rod 318 between the uppermost position of the flip rod 318 and the lowermost position of the flip rod 318, In one embodiment, the actuator 800 includes a minimum stroke of 7″ and a minimum push/pull force of 10 pounds. In one example, the actuator 800 has a 25 pound pushing/pulling capacity with a stroke length of the 7.87″ and a speed of 2″ per second. In one embodiment the actuator 800 is a standard actuator with limit switches and a duty cycle of 10 seconds on/seconds off as required to freeze the shaped ice pieces 114 (approximately 2-5 minutes). In another embodiment, the actuator 800 is a high force actuator with limit switches and a duty cycle of 1 minute on/3 minutes off.

Referring next to FIG. 9, a detail of the actuator 800 of FIG. 8 is shown. Shown are the first sidewall 308, the second sidewall 324, the flip rod 318, the vertical tracks 316, the actuator 800 and a shock absorber 900. Other portions of the shaped ice unit 204 have been omitted for clarity.

The actuator 800 in one embodiment of the invention includes the shock absorber 900 coupled to a top portion, of the actuator 800 and configured to improve the coupling of the bottom mold 304 to the top mold 302 as the flip rod 318 is moved to the uppermost position, without limiting the range of the actuator 800. The actuator 800 is coupled to the flip rod 318 with only one rotational degree of freedom around a longitudinal axis of die rod 318, allowing for the bottom mold 304 to spin as the bottom mold 304 is raised and lowered. A bearing-like connection between the actuator 800 and the flip rod 318 is preferred as it would allow for the flip rod 318 to rotate as it pushes or pulls the bottom mold 304.

Referring next to FIG. 10, a portion of the top mold 302 is shown in one embodiment of the present invention. Shown are refrigerant piping 1000 and an electric resistance wire 1002.

Refrigerant piping 1000 is coupled to the compressor, and is used to cool and freeze the ice pieces 114. As shown, the refrigerant piping 1000 runs along the top of the top mold 302 in a generally zig-zag pattern. The refrigerant piping 1000 may include parallel piping, with a portion of piping 1000 for one top mold 302 in parallel with a portion of piping 1000 for another top mold 302, as shown in FIG. 10. It will be appreciated that other configurations and cooling/freezing layouts are possible as known in the prior art. The cooling system is operatively coupled to and controlled by the control module 106.

The top mold 302 also includes the electric resistance wire 1002 coupled to the top of the top mold 302. The electric resistance wire 1002 is operatively coupled to and controlled by the control module 106, and receives electrical current from the electrical system of the ice making system 100. The electrical resistance wire 1002 is configured to provide heat to the ice pieces 114 within the top mold 302. After the ice pieces 114 have been formed, but before the bottom mold 304 is moved downward, the control module 106 causes the electrical resistance wire 1002 to heat briefly, such that the ice pieces 114 are loosened from the mold 302. This allows the ice pieces 114 to separate from the top mold 302 as the bottom mold 304 moves downward.

Referring next to FIG. 11, the top mold 302 is shown in one embodiment of the present invention. The mold 302 is shown with a bottom side (a cavity side 1102) facing upward for clarity, although when installed in the shaped ice unit 204 the cavity side 1102 will be facing downward. Shown are the plurality of water access holes 338, the plurality of top mold cavities 326, the cavity side 1102, and a plurality of mounting holes 1104.

As shown in FIG. 11, the top mold 302 is rectilinear in shape, with a thickness to accommodate the three-dimensional ice shape and the water access holes 338. The bottom mold 304 is not shown, but is configured to couple to the cavity side 1102 of the top mold 302 to form the desired three-dimensional shape cavity. In one embodiment, the bottom mold cavities 306 mirror the top mold cavities 326, forming symmetrical shapes. For example, the cavities 326 shown in FIG. 11, paired with a mirrored bottom mold 304, would produce spheres and cubes. In other embodiments, the bottom mold 304 is not a mirror image of the top mold 302. Other mold shapes may be of any shape capable of being formed into a mold, and having the subsequent shaped ice piece 114 removed from the mold after the bottom and top molds 302, 304 are separated. The top mold 302 and the bottom mold 304 may be made from food-grade metal or other material (e.g. plastic) suitable for food grade and the freezing and unmolding process. In a preferred embodiment, the molds 302, 304 are food-grade stainless steel. In one embodiment, the cavities 306, 326 are formed by stamp-pressing a sheet of metal to create the cavities 306, 326. In other embodiments, the top mold 302 and the bottom mold 304 may be formed by a molding process. Other suitable forming methods as known in the art may be used for forming the molds 302, 304.

In one embodiment, molds 302, 304 included in she shaped ice system 100 are configured to produce approximately 50 unique ice shapes.

In the top mold 302 shown in FIG. 11, 12 cavities 326 are arranged on the cavity side 1102 of the top mold 302 in a 4×3 grid arrangement. On a left side of the top mold 302, the cavities 326 form one portion of a spherical mold. On a right side of the top mold 302, the cavities 326 form one portion of a cubical mold. It will be appreciated that the cavities 326 may be all the same, or all different, or some other combination of shapes. While 12 cavities 326 are shown, more or fewer cavities 326 may be includes in the top mold 302 or bottom mold 304.

The water access holes 338 provide for water to enter the top mold 302, as previously described. The top mold 302 includes the plurality of mounting holes 1104 for removably mounting the top mold 302 to the shaped ice unit 204. Four mounting holes 1104 are shown, one at each corner of the top mold 302, with the holes 1104 oriented vertically. In one embodiment, screws are used to couple the top mold 302 to the shaped ice unit 204. It will be appreciated that other methods of removable coupling may be provided, for example, a slide-in frame coupling, clamping, or other means of removable coupling.

In one embodiment, the top mold 302 and the bottom mold 304 are configured to produce shaped ice pieces 114 each having a volume of approximately 0.75 cubic inches. The size of the shaped ice pieces 114 is chosen for having a shorter freezing time and greater durability, but it will be appreciated that molds 302, 304 for larger or smaller volume shaped ice pieces 114 may also be used with the shaped ice system 100. Any ice shape may be used provided that the shape is unmoldable (i.e. includes no undercut corners). Each top mold 302 also includes a standard location and size of access holes 338 to allow for interchangeability of the top mold 302.

The top mold 302 and the bottom, mold 304 may be of plastic, metal, or any other material suitable for the freezing/dispensing process and safe for food items (i.e. in compliance with all applicable codes and standards).

Referring next to FIG. 12, a flow chart for forming shaped ice pieces 114 in one embodiment of the present invention is shown. Shown are a select ice shape step 1200, a dispense ice command step 1202, a dispensing step 1204, and the make additional ice step 1206.

In the select ice shape step 1200, the user uses the user interface 108 to select the desired type of shape ice pieces 114. In one embodiment, the type of shaped ice pieces 114 is determined by a category selection. In another embodiment, multiple selections may be made for the shaped ice dispensation (e.g., as shown below in FIG. 12 up to three categories may be selected). The user may also select an amount of ice pieces 114 to dispense, or the amount of ice pieces 114 may be preset. The user interface 108 sends the user selection to the control module 106.

In the next step, the dispense ice command step 1202, the control module 106 sends a command to the storage and dispensing module 110 to dispense the ice pieces 114 from the storage bin 112 corresponding to the desired ice type. The process then proceeds to the dispensing step 1204.

During the dispensing step 1204, the dispensing apparatus for the selected storage bin 112 dispenses the selected ice pieces 114 to the user.

In the final make additional ice step 1206, the control module 106 sends commands to the ice maker module 104 as required to form an additional amount of ice pieces 114 of the selected ice shape or shapes. The amount of shaped ice pieces 114 may be the amount to replace the amount dispensed, or the amount of shaped ice pieces 114 may be an amount to fill the storage bin 112 to a preset volume.

Referring next to FIG. 13, a user interface menu 1300 is shown is one embodiment of the present invention. Shown are the user interface menu 1300, a plurality of category icons 1302, and a category selection display 1304.

In one embodiment of the invention, a touch-screen display is used both as the display and the user interface 108. The user interface menu 1300 shown in FIG. 12 is a selection screen used for the user to select at least one category of shaped ice pieces 114. A plurality of category icons 1302 is shown arranged on the screen. The category icons 1302 represent the type of the shaped ice pieces 114 to be dispensed. In the exemplary user interface menu 1300, the categories shown are “Sports”, “Movies”, “animals”, “Holiday”, “Games”, and “Classic”. Each category icon 1302 includes text of the category and a graphical image representing the category (e.g., a tiger graphic for the “Animals” category). The category icons 1302 also represent the selection area of the screen for selection of that category, i.e. the category icon 1302 also functions as a button for selection of that category.

The exemplary user interface menu 1300 also includes the category selection display 1304 showing the categories that the user has selected. As shown in FIG. 13, the three lines indicate selection of up to three categories is available, and no categories have been selected. When selected, the categories are indicated by a smaller version of the category icon 1302. When the category is selected, in some embodiments a display of sub-category icons will be shown.

In the embodiment shown, each category represents a plurality of different ice-shape pieces 114 which are dispensed together. For example, the holiday category could dispense ice shapes comprising heart shapes, pumpkin shapes, and clover shapes. In some embodiments, 3-5 different ice shapes are included in each category.

Many of the functional units described in this specification have been labeled as modules, in order to more particularly emphasize their implementation independence. For example, a module may be implemented as a hardware circuit comprising custom VLSI circuits or gate arrays, off-the-shelf semiconductors such as logic chips, transistors, or other discrete components. A module may also be implemented in programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices or the like.

Modules may also be implemented in software for execution by various types of processors. An identified, module of executable code may, for instance, comprise one or more physical or logical blocks of computer instructions that may, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified module need not be physically located together, but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the module and achieve the stated purpose for the module.

Indeed, a module of executable code could be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices. Similarly, operational data may be identified and illustrated herein within modules, and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices, and may exist, at least partially, merely as electronic signals on a system or network.

While the invention herein disclosed has been described by means of specific embodiments, examples and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. 

What is claimed is:
 1. An automatic shaped ice system comprising: a control module coupled and configures to operatively control an ice maker module, an ice dispensing module, and a user interface; the ice maker module including a plurality of molds for forming a plurality of shaped ice pieces, the module configured to receive water from a water source and supply the water to at least one mold, freeze the at least one mold, and remove the plurality of shaped ice pieces from the molds, wherein the plurality of molds produces a plurality of ice shapes; the ice dispensing module configured to receive the ice shapes from the ice maker module and store the ice shapes in a plurality of storage bins, wherein each storage bin stores a combination of ice shapes; and the user interface configured to receive a user selection for a combination of ice shapes stored in at least one of the storage bins, whereby a selected combination of ice shapes is dispensed by the ice system.
 2. The automatic shaped ice system of claim 1, the ice maker module further comprising a plurality of shaped ice units, each shaped ice unit including a stationary top mold located proximate to a top of the shaped ice unit, and a movable bottom mold located below the top mold and configured to removably couple to the top mold, whereby cavities for forming three-dimensional shaped ice pieces are formed when the top mold is coupled to the bottom mold.
 3. The automatic shaped ice system of claim 2, wherein the coupling of the top mold to the bottom mold is a watertight coupling.
 4. The automatic shaped ice system of claim 3, wherein the bottom mold is movable from a molding position, wherein the bottom mold is coupled to the top mold, to an unmolding position, wherein the bottom mold, after the shaped ice pieces are formed, is moved downward away from the top mold and rotated approximately 180 degrees, whereby the shaped ice pieces in the bottom mold fail from the bottom mold.
 5. The automatic shaped ice system of claim 4, wherein the shaped ice pieces fall from the bottom mold into one of the plurality of storage bins.
 6. The automatic shaped ice system of claim 1, the control module comprising at least one processor and a non-transitory memory coupled to the processor.
 7. The automatic shaped ice system of claim 1, wherein the user interface is a touchscreen interface.
 8. The automatic shaped ice system of claim 7, wherein the user interface displays a plurality of category icons.
 9. The automatic shaped ice system of claim 8, wherein the user selection comprises selecting by a user of at least one of the category icons displayed on the user interface.
 10. The automatic shaped ice system of claim 1, further comprising a housing enveloping the control module, the ice maker module, and the ice dispensing module.
 11. The automatic shaped ice system of claim 2, the ice maker module further comprising a water tank interposed between the water source and the shaped ice units.
 12. The automatic shaped ice system of claim 2, the ice maker module further comprising a water injection manifold interposed between the water source and the shaped ice units, the water injection manifold operatively coupled to the control module, whereby flow of water to each shaped ice unit is controlled by the control module via the water injection manifold.
 13. A process for an automatic shaped ice system comprising the steps of: selecting, by a user from a user interlace of the automatic shaped ice system, of at least one category of shaped ice, whereby a control module coupled to the user interlace receives a category selection; sending, by the control module, in response to receiving the category selection, of a dispensing command to a storage and dispensing module of the automatic shaped ice system; dispensing of shaped ice from at least one storage bin of the storage and dispensing module, the storage bin storing a plurality of shaped ice pieces, wherein the at least one storage bin corresponds to the at least one category; sending, by the control module, of at least one command to an ice maker module of the automatic shaped ice system for forming additional shaped ice pieces.
 14. The process for using the automatic shaped ice system of claim 13, wherein at least one of the at least one category of shaped ice is selected from a group consisting of a movie category, an animal category, a holiday category, a games category and a classic category.
 15. The process for using the automatic shaped ice system of claim 13, wherein each storage bin includes at least three different ice shapes.
 16. The process for using the automatic shaped ice system of claim 13, wherein the user interface displays a plurality of category icons, and whereby the selecting of the at least one category of shaped ice further includes selecting of at least one category icon.
 17. A shaped ice unit for an automatic shaped ice system, comprising: a frame including two vertical sidewalls located on opposite sides of the frame; a generally vertical track located in each sidewall; a top mold removably coupled to a portion of the frame near the top of the sidewalls, wherein the top mold is located between the sidewalls, and wherein the top mold is oriented in a horizontal position, and configured to receive water from a water line of the automatic shaped ice system, and wherein the top mold includes a plurality of downward-facing cavities for forming shaped ice pieces; a bottom mold located between the sidewalls and movably coupled to each sidewall track, whereby at a top position the bottom mold is coupled to the top mold, the bottom mold including a plurality of cavities configured to form three-dimensional shapes when matched with the cavities of the top mold; two flanges coupled to the bottom mold, wherein each arm is coupled proximate to the sidewall, each flange generally perpendicular to a horizontal plane of the bottom mold and extending generally downward when the bottom mold is in a horizontal position, each flange including two generally parallel arms and a channel formed between the arms; two track plates oriented parallel to the sidewalls, each track plate pivotally coupled at one end to an inside face of the proximate sidewall by an upper bolt located proximate to the top mold, each track plate including a curved rod track; a cylindrical rod coupled to the bottom mold and oriented horizontally, the rod passing through each rod track and each vertical track and spanning between the sidewalls, whereby movement of the rod is constrained by the rod tracks and the vertical tracks, and wherein when the bottom mold is in the top position the rod is in a top position; and a pivot bolt projecting inward from each sidewall and extending through each flange channel, whereby when the rod is moved downward from the top position, the bottom mold moves downward to a bottom position, and rotates approximately 180 degrees, whereby ice pieces formed when the top mold is coupled to the bottom mold are inverted, whereby gravity causes the ice pieces to fail from the bottom mold.
 18. The shaped ice unit of claim 17, wherein the plurality of cavities are configured to produce approximately the same ice shapes.
 19. The shaped ice unit of claim 17, wherein the plurality of cavities are configured to produce at least two different ice shapes.
 20. The shaped ice unit of claim 17, further comprising an actuator coupled to the rod, the actuator configured to move the rod between the rod top position and the rod bottom position. 